Water filtration using immersed membranes

ABSTRACT

A process for operating filtering membranes submerged in a tank involves, in one aspect, periodically deconcentrating the tank by partially emptying and refilling the tank with fresh water. The emptying and refilling may be performed generally simultaneously or sequentially. In another embodiment, the membrane modules are arranged in a series of filtration zones between a feed water inlet and a retentate outlet of a tank and the zone adjacent the outlet is emptied and refilled.

This is a continuation of U.S. patent application Ser. No. 11/006,626filed Dec. 8, 2004 which is a continuation of U.S. patent applicationSer. No. 10/098,365, filed Mar. 18, 2002; which is a division of U.S.patent application Ser. No. 09/444,414, filed Nov. 22, 1999; which is anapplication claiming the benefit under 35 USC 119(e) of U.S. provisionalpatent application No. 60/109,520, filed Nov. 23, 1998. U.S. applicationSer. Nos. 11/006,626, 10/098,365, 09/444,414 and 60/109,520 areincorporated herein, in their entirety, by this reference to them.

FIELD OF THE INVENTION

This invention relates to the use of ultrafiltration or microfiltrationmembranes to treat water, and more particularly to the design andoperation of reactors which use immersed membranes as part of asubstantially continuous process for filtering water containing lowconcentrations of solids, for example for producing potable water.

BACKGROUND OF THE INVENTION

Immersed membranes are used for separating a permeate lean in solidsfrom tank water rich in solids. Feed water flowing into a tankcontaining immersed membranes has an initial concentration of solids.Filtered permeate passes through the walls of the membranes under theinfluence of a transmembrane pressure differential between a retentateside of the membranes and a permeate side of the membranes. As filteredwater is permeated through the membranes and removed from the system,the solids are rejected and accumulate in the tank. These solids must beremoved from the tank in order to prevent rapid fouling of the membraneswhich occurs when the membranes are operated in water containing a highconcentration of solids.

In a continuous fully mixed process, there is typically a continuousbleed of tank water rich in solids, which may be called retentate.Unfortunately, while this process preserves a mass balance, the tankwater must contain a high concentration of pollutants or the processwill generate large volumes of retentate.

For example, if a fully mixed continuous bleed process is operated at arecovery rate of 95% (ie. 95% of the feed water becomes filteredpermeate), only 5% of the feed water leaves the tank as retentate. Topreserve a mass balance of solids, the retentate must have aconcentration of pollutants 20 times that of the feed water. Theconcentration of solids in the retentate, however, is the same as theconcentration of solids in the tank since the retentate is drawn fromthe tank water. Accordingly, the tank water has a high concentration ofpollutants at all times. Operating at a lower recovery rate, 80% forexample, results in tank water having a lower concentration of solidsbut the cost of transporting excess feedwater and then disposing ofexcess retentate also increases.

Another process involves filtering in a batch mode. For example, PCTPublication No. WO 98/28066 describes a process in which retentate isnot withdrawn continuously. Instead, the tank water is drained to removethe accumulated solids from time to time. The tank is then refilled withfresh feed water and operation continues. While regular operation isinterrupted in this method, there is a period directly after the tank isrefilled in which the membranes are operated in relatively solids leantank water. For feed water with low suspended solids, the intervalsbetween drainings may be long enough that the benefit gained by emptyingthe tank offsets the loss in production time.

With either process, as filtered water is permeated through themembranes the solids in the tank water foul the membranes. The rate offouling is related to the concentration of solids in the tank water andcan be reduced but not eliminated in a fully mixed continuous bleedprocess by lowering the recovery rate. Further, the solids may bepresent in the feed water in a variety of forms which contribute tofouling in different ways. To counter the different types of fouling,many different types of cleaning regimens may be required. Such cleaningusually includes both physical cleaning and chemical cleaning.

The most frequently used methods of physical cleaning are backwashingand aeration. These methods are typically performed frequently and thusmay influence the filtering process. In backwashing, permeation throughthe membranes is stopped momentarily. Air or water flow through themembranes in a reverse direction to physically push solids off of themembranes. In aeration, bubbles are produced in the tank water below themembranes. As the bubbles rise, they agitate or scrub the membranes andthereby remove some solids while creating an air lift effect andcirculation of the tank water to carry the solids away from themembranes. These two methods may also be combined. For example, in afully mixed continuous bleed process as described above, aeration may beprovided continuously and the membranes backwashed periodically whilepermeation is temporarily stopped. Alternately, PCT Publication No. WO98/28066 mentioned above describes a process in which permeationcontinues for 15 minutes and then stops while the membranes are aeratedfor 2 minutes and 15 seconds. After the first minute of aeration, themembranes are backwashed for 15 seconds.

Chemical cleaning is typically performed less frequently thanbackwashing or aeration. According to one class of methods, permeationis stopped and a chemical cleaner is backwashed through the membranes.In some cases, the tank is emptied during or after the cleaning event sothat the chemical cleaner can be collected and disposed of. In othercases, the tank remains filled and the amount of chemical cleaner in acleaning event is limited to an amount that is tolerable for theapplication.

Known fully mixed continuous bleed processes rely heavily on aeration,backwashing and chemical cleaning to maintain membrane permeability. Thecleaning methods all damage the membranes over time. In addition,backwashing with permeate or chemical cleaner interrupts permeation andreduces the yield of the process. Aeration requires energy which add tothe operating costs of a reactor and the resulting circulation of tankwater requires significant open space in the tank. Processes thatinvolve frequently draining the tank require less cleaning in somecases. Particularly in large systems, however, loss in production timecan be high because it is difficult to drain a large municipal orindustrial tank quickly. In some cases, the tank is raised and fittedwith a large number of drains to promote rapid draining but thesetechniques increase the cost of an installation.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a process andapparatus which uses immersed filtering membranes as part of asubstantially continuous process for filtering water containing lowconcentrations of solids, for example to produce potable water.

In one aspect, the invention provides an improvement to a process forfiltering water using membranes immersed in an open tank. Theimprovement includes reducing the concentration of solids in the waterin the tank from time to time through deconcentrations. Thedeconcentrations are performed by withdrawing retentate rich in solidsand simultaneously replacing it with a similar volume of feed water suchthat the membranes remain immersed during the deconcentration andpermeation is not interrupted. The volume of retentate removed in adeconcentration is between 40% and 300% of the volume of water normallyin the tank. At the end of a deconcentration, the water in the tank has40% or less of the average concentration of solids in the tank beforethe deconcentration. Preferably, one or more of aeration or backwashingare biased towards a later part of a period between deconcentrations.

In another aspect, the invention provides an immersed membrane filter.One or more membrane modules are placed in an open tank spacedconsecutively along a general flow path between an inlet and an outlet.The distance between membrane modules (measured along the flow path) isless than one half of the length of each membrane module (measured alongthe flow path). The total length of all of the membrane modules(measured along the flow path) excluding the distance between them(along the flow path) is at least twice the width of the membranemodules (measured perpendicular to the flow path). A similar flux ofpermeate is collected from the various membrane modules. Agitators,preferably aerators, are provided below the membrane modules andoperated substantially throughout permeation to entrain tank wateraround the membrane modules and flow the water containing solids upwardsthrough the modules. Tank water flows through a plurality of membranemodules sequentially in relation to the flow path before leaving thetank at the outlet. Preferably, one or more of aeration, backwashing andpacking density are biased towards the outlet end of the tank. The tankmay be deconcentrated from time to time as described above.

In another aspect, the invention provides an open tank divided into aplurality of sequential filtration zones. Partitions between thefiltration zones substantially prevent mixing between the filtrationzones but for permitting water containing solids to flow from the firstfiltration zone to the last filtration zone through the filtration zonesin sequence. One or more membrane modules are placed in each filtrationzone and a similar permeate flux is withdrawn from each filtration zone.A non-porous casing around the one or more membrane modules in eachfiltration zone provides a vertical flow channel through the one or moremembrane modules. Tank water flows downwards through the one or moremembrane modules in each filtration zone. A plurality of passagesconnect the bottom of the vertical flow channel in one filtration zoneto the top of the vertical flow channel of another filtration zone andpermit the tank water to flow from the first filtration zone to the lastfiltration zone through the filtration zones consecutively. The passagesinclude a weir at the tops of the partitions. Preferably, packingdensity, aeration and backwashing are biased towards an outlet end ofthe tank. The tank may be deconcentrated from time to time as describedabove. Alternatively, the last filtration zone may be deconcentrated bydraining and refilling it while permeation from the last filtration zoneis stopped.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will now be described below withreference to the following figures:

FIG. 1 is a schematic representation of a general immersed membranereactor.

FIGS. 2, 3 and 4 are representations of various membrane modules.

FIG. 5A is a schematic representation of an embodiment of the inventionwith a long aerated filtration train.

FIG. 5B is a schematic cross section of the embodiment of FIG. 5A.

FIG. 6 is an elevation view of a membrane module adapted for use with afiltering reactor having membrane modules in series.

FIG. 7 is a plan view of the membrane module of FIG. 2.

FIG. 8 is a schematic representation of a filtering reactor havingmembrane modules in series.

FIGS. 9 and 10 show tanks with alternate shapes.

FIGS. 11 through 16 are charts showing the results of modellingexperiments performed according to an embodiment similar to that of FIG.5.

FIG. 17 is a chart showing the results of an experiment performed withan embodiment similar to that of FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

General Filtration Process

The following description of a filtration process applies generally tothe embodiments which are described further below unless inconsistentwith the description of any particular embodiment.

Referring now to FIG. 1, a first reactor 10 is shown for treating aliquid feed having solids to produce a filtered permeate substantiallyfree of solids and a consolidated retentate rich in solids. Such areactor 10 has many potential applications such as separating cleanwater from mixed liquor in a wastewater treatment plant or concentratingfruit juices etc., but will be described below as used for creatingpotable water from a natural supply of water such as a lake, well, orreservoir. Such a water supply typically contains colloids, suspendedsolids, bacteria and other particles which must be filtered out and willbe collectively referred to as solids.

The first reactor 10 includes a feed pump 12 which pumps feed water 14to be treated from a water supply 16 through an inlet 18 to a tank 20where it becomes tank water 22. Alternatively, a gravity feed may beused with feed pump 12 replaced by a feed valve. During permeation, thetank water 22 is maintained at a level which covers a plurality ofmembranes 24. Each membrane 24 has a permeate side which does notcontact the tank water 22 and a retentate side which does contact thetank water 22. Preferably, the membranes 24 are hollow fibre membranesfor which the outer surface of the membranes 24 is preferably theretentate side and the lumens 25 of the membranes 24 are preferably thepermeate side.

Each membrane 24 is attached to at least one but preferably two headers26 such that the ends of the membranes 24 are surrounded by pottingresin to produce a watertight connection between the outside of themembranes 24 and the headers 26 while keeping the lumens 25 of themembranes 24 in fluid communication with a permeate channel in at leastone header 26. Membranes 24 and headers 26 together form of a membranemodule 28. The permeate channels of the headers 26 are connected to apermeate collector 30 and a permeate pump 32 through a permeate valve34. When permeate pump 32 is operated and permeate valve 34 opened, anegative pressure is created in the lumens 25 of the membranes 24relative to the tank water 22 surrounding the membranes 24. Theresulting transmembrane pressure is typically between 1 kPa and 150 kPaand more typically between 10 kPa and 70 kPa and draws tank water 22(then referred to as permeate 36) through membranes 24 while themembranes 24 reject solids which remain in the tank water 22. Thus,filtered permeate 36 is produced for use at a permeate outlet 38 throughan outlet valve 39. Periodically, a storage tank valve 64 is opened toadmit permeate 36 to a storage tank 62. The filtered permeate 36 mayrequire post treatment before being used as drinking water, but shouldhave acceptable levels of colloids and other suspended solids.

In a municipal or industrial reactor 10, discrete units each having aplurality of membranes 24 are assembled together into larger unitscalled membrane modules 28 which may also be referred to as a cassette.Examples of such membrane modules 28 are shown in FIGS. 2, 3 and 4 inwhich the discrete units are rectangular skeins 8. Each rectangularskein 8 typically has a bunch between 2 cm and 10 cm wide of hollowfibre membranes 24. The hollow fibre membranes 24 typically have anoutside diameter between 0.4 mm and 4.0 mm and are potted at a packingdensity between 10% and 40%. The hollow fibre membranes 24 are typicallybetween 400 mm and 1,800 mm long and mounted with between 0.1% and 5%slack. The membranes 24 have an average pore size in the microfiltrationor ultrafiltration range, preferably between 0.003 microns and 10microns and more preferably between 0.02 microns and 1 micron. Thepreferred number of membrane modules 28 varies for differentapplications depending on factors such as the amount of filteredpermeate 36 required and the condition of the feed water 14.

Referring to FIG. 2, for example, a plurality of rectangular skeins 8are connected to a common permeate collector 30. Depending on the lengthof the membranes 24 and the depth of the tank 20, the membrane modules28 shown in FIG. 2 may also be stacked one above the other. Referring toFIGS. 3 and 4, the rectangular skeins 8 are shown in alternateorientations. In FIG. 3, the membranes 24 are oriented in a horizontalplane and the permeate collector 30 is attached to a plurality ofrectangular skeins 8 stacked one above the other. In FIG. 4, themembranes 24 are oriented horizontally in a vertical plane. Depending onthe depth of the headers 26 in FIG. 4, the permeate collector 30 mayalso be attached to a plurality of these membrane modules 28 stacked oneabove the other. The representations of the membrane modules 28 in FIGS.2, 3, and 4 have been simplified for clarity, actual membrane modules 28typically having rectangular skeins 8 much closer together and a largecassette often having many more rectangular skeins 8.

Membrane modules 28 can be created with skeins of different shapes,particularly cylindrical, and with skeins of looped fibres attached to asingle header. Similar modules or cassettes can also be created withtubular membranes in place of the hollow fibre membranes 24. For flatsheet membranes, pairs of membranes are typically attached to headers orcasings that create an enclosed surface between the membranes and allowappropriate piping to be connected to the interior of the enclosedsurface. Several of these units can be attached together to form acassette of flat sheet membranes.

Commercially available membrane modules 28 include those based on ZW 500units made by ZENON Environmental Inc. and referred to in the examplesfurther below. Each ZW 500 unit has two rectangular skeins of hollowfibre membranes having a pore size of approximately 0.1 microns orientedas shown in FIG. 2 with a total membrane surface area of approximately47 square metres. In plan view, each ZW 500 unit is about 700 mm longand about 210 mm wide. Typically, several ZW 500 units are joinedtogether into a cassette to provide a plurality of parallel rectangularskeins 8. For example, a membrane module 28 of 8 ZW 500 units is about1830 mm by 710 mm, some additional space being required for frames,connections and other related apparatus.

Referring again to FIG. 1, tank water 22 which does not flow out of thetank 20 through the permeate outlet 38 flows out of the tank 20 througha drain valve 40 and a retentate outlet 42 to a drain 44 as retentate 46with the assistance of a retentate pump 48 if necessary. The retentate46 is rich in the solids rejected by the membranes 24.

To provide aeration, an air supply pump 50 blows ambient air, nitrogenor other suitable gases from an air intake 52 through air distributionpipes 54 to aerator 56 which disperses scouring bubbles 58. The bubbles58 rise through the membrane module 28 and discourage solids fromdepositing on the membranes 24. In addition, where the design of thereactor 10 allows the tank water 22 to be entrained in the flow ofrising bubbles 58, the bubbles 58 also create an air lift effect whichin turn circulates the local tank water 22.

To provide backwashing, permeate valve 34 and outlet valve 39 are closedand backwash valves 60 are opened. Permeate pump 32 is operated to pushfiltered permeate 36 from retentate tank 62 through backwash pipes 61and then in a reverse direction through permeate collectors 30 and thewalls of the membranes 24 thus pushing away solids. At the end of thebackwash, backwash valves 60 are closed, permeate valve 34 and outletvalve 39 are re-opened and pressure tank valve 64 opened from time totime to re-fill retentate tank 62.

To provide chemical cleaning, a cleaning chemical such as sodiumhypochlorite, sodium hydroxide or citric acid are provided in a chemicaltank 68. Permeate valve 34, outlet valve 39 and backwash valves 60 areall closed while a chemical backwash valve 66 is opened. A chemical pump67 is operated to push the cleaning chemical through a chemical backwashpipe 69 and then in a reverse direction through permeate collectors 30and the walls of the membranes 24. At the end of the chemical cleaning,chemical pump 67 is turned off and chemical pump 66 is closed.Preferably, the chemical cleaning is followed by a permeate backwash toclear the permeate collectors 30 and membranes 24 of cleaning chemicalbefore permeation resumes.

Preferably, aeration and backwashing clean the membranes sufficiently sothat permeation can continue over extended periods of time. Permeatebackwashes typically last for between 5 seconds and two minutes and aretypically performed between once every 5 minutes and once every 3 hours.If such permeate backwashes are performed between more intensiverestorative cleaning events, the filtering process is still consideredcontinuous since permeation is only stopped momentarily. Similarly, ifchemical cleaning is performed in short duration chemical backwasheswhile the tank 20 remains full of tank water 22, the process is stillconsidered continuous. In the cases, however, flow rates of permeate 36,retentate 46 and feed water 14 are calculated as average flow rates overa day or such longer period of time as appropriate. In the descriptionof the embodiments and examples which follow, flow rates of processesthat are periodically interrupted as described above are measured asaverage flow rates unless they are described otherwise.

Rapid Flush Deconcentration

Referring still to FIG. 1, in rapid flush deconcentration the filtrationprocess proceeds as a number of repeated cycles which end with aprocedure to deconcentrate the tank water 22, the procedure beingreferred to as a deconcentration. The cycles usually begin at the end ofthe preceding deconcentration. Some cycles, however, begin when a newreactor 10 is first put into operation or after intensive restorativecleaning or other maintenance procedures which require the tank 20 to beemptied. Regardless, the cycle begins with the tank 20 filled withmembranes 24 submerged in tank water 22 with an initial concentration ofsolids similar to that of the feed water 14.

At the start of a cycle, permeate pump 32 is turned on and sucks tankwater 22 through the walls of the membranes 24 which is discharged asfiltered permeate 36. Drain valves 40 initially remain closed and theconcentration of solids in the tank water 22 rises. While drain valves40 are closed, the feed pump 12 continues to pump feed water 14 into thetank 20 at about the same rate that filtered permeate 36 leaves the tanksuch that the level of the tank water 22 is essentially constant duringpermeation. Aeration and backwashing are provided as required.

After a desired period of time, the tank water 22 is deconcentrated. Thedesired period of time between deconcentrations may be based on theconcentration of solids in the tank water 22 but preferably is chosen toachieve a desired recovery rate. For ZW 500 membrane modules used withtypical feed water supplies operating with constant aeration andperiodic backwashing between deconcentrations, a recovery rate of 95%(ie. 95% of the feed water becomes filtered permeate) or more can bemaintained and is preferred when an operator wishes to discharge minimalamounts of consolidated retentate 46. This recovery rate results in aconcentration of solids in the tank water 22 at the start of thedeconcentrations approximately 20 times that of the feed water. However,the inventors have observed in tests performed with continuous membranefiltration processes and feed water having turbidity of 0.5 to 0.6 ntuand apparent colour of 33 Pt. Co. units that the rate at which thepermeability of membranes decreases over time rises dramatically whenthe recovery rate is increased to over 93%. Accordingly, if the volumeof wasted retentate is a minor factor, then the period betweendeconcentrations may be chosen to yield a 90% to 95% recovery rate orless. Typical cycle times when using ZW 500 units range from about 2 to3 hours at a recovery rate of 90% and 4 to 5 hours at a recovery rate of95% although cycle times will vary for other membrane modules.

The deconcentrations comprise a rapid flush of the tank water 22 whilemaintaining the level of tank water 22 above the level of the membranes24 and continuing permeation. To perform the rapid flushdeconcentration, the drain valves 40 are opened and retentate pump 48rapidly draws retentate 46 rich in solids out of the tank 20 if gravityflow alone is insufficient. Simultaneously, feed pump 12 increases theflow rate of feed water 14 into the tank 20 by an amount correspondingto the flow rate of retentate 46 out of the tank 20. Preferably, theretentate 46 is removed at a sufficient rate, assisted by retentate pump48 if necessary, such that the tank water 22 is not dilutedsignificantly by mixing with incoming feed water 14 before it is flushedout of the tank 20. Some dilution necessarily occurs, and it ispreferable to stop the flow of consolidated retentate 46 while the tankwater 22 still has a concentration of solids greater than theconcentration of solids in the feed water 14 to avoid withdrawing anunacceptably high volume of consolidated retentate 46. However, thevolume of consolidated retentate 46 withdrawn may exceed the volume ofwater in the tank 20. Preferably, aeration and any other source ofmixing are turned off to minimize dilution of the retentate 46 andbetween 100% to 150% of the average volume of the tank water 22 isdischarged during the rapid flush deconcentration. If aeration must beleft on to provide continued cleaning, a higher volume of tank water 22is discharged. More preferably, between 100% and 130% of the volume ofthe average volume of the tank water 22 is discharged. The totaldischarge time is typically less than 20 minutes and preferably lessthan 10 minutes. If there is aeration or other mixing at the time of therapid flush, then between 150% and 300%, more preferably between 150%and 200%, of the average volume of the tank water 22 is discharged andthe total discharge time is less than 25 minutes. After thedeconcentration, the tank water 22 preferably has less than 40% of theconcentration of solids that was present in the tank water 22 prior tothe deconcentration. Where the feed water 14 has high turbidity or wherehigh recovery rates are used, however, the tank water 22 after adeconcentration preferably has less than 20% of the concentration ofsolids that was present in the tank water 22 prior to thedeconcentration. Retentate 46 is typically disposed of down a drain 44to a sewer or to the source of water where it initially came from.

Like a process without deconcentrations, there must still be a balanceof solids and water between the feed water 14, retentate 46 and filteredpermeate 36 over repeated cycles. Thus for a selected recovery rate, theaverage amount of solids in the retentate 46 in a process withdeconcentrations will be the same as for a process withoutdeconcentrations. Since the retentate 46 is typically diluted in rapidflush deconcentrations, however, the tank water 22 must have a higherconcentration of solids immediately before a deconcentration compared tothe constant concentration of solids in a fully mixed continuous bleedprocess. By replacing at least a substantial portion of the existingtank water 22 with fresh feed water 14, however, permeation continues inthe next cycle with relatively clean tank water 22 until solids againbuild up in the tank water 22 and another deconcentration is performed.Thus the average concentration of solids in the tank water 22 over timeis an intermediate value between that of the feed water 14 and theconsolidated retentate 46 and less than the constant concentration ofsolids in a fully mixed continuous bleed process at the same recoveryrate. While the tank water 22 has a lower concentration of solids themembranes foul less rapidly. Accordingly, increased flux of permeate 36is observed at a set transmembrane pressure or a higher transmembranepressure can be used at the beginning of a cycle without excessivefouling of the membranes 24.

Preferably, a reduced flow rate of air bubbles 58 is initially suppliedto the tank 20 when the concentration of solids is low and the membranes24 foul more slowly. As the concentration of solids rises in the tankwater 22, the flow rate of air is also increased. Alternately, aerationis only provided directly before the deconcentration. In this way,excess air is not supplied while the concentration of solids is low inthe tank water 22. Similarly, the frequency or duration of backwashingmay be decreased when the concentration of solids in the tank water 22is low to minimize loss in production due to backwashing. To the extentthat aeration can be made to coincide with backwashing, theeffectiveness of the aeration is increased since is does not have towork against the transmembrane pressure.

Despite the aeration, periodic backwashing, and periodicdeconcentrations of the tank water 22, long term fouling of themembranes may still occur, although more slowly than in a processwithout deconcentrations. As long term fouling occurs, power to thepermeate pump 32 may be increased to increase the transmembrane pressureacross the walls of the membranes 24 to compensate for the reducedpermeability. Eventually, a specified maximum transmembrane pressure forthe system or a minimum tolerable permeability of the membranes 24 willbe reached. At this time, intensive restorative cleaning is done. ForZeeWeed (a trade mark) brand membranes 24, intensive cleaning ispreferably done when the transmembrane pressure exceeds 54 kPa or thepermeability drops below 200 litres per square metre per hour per bar(L/m2/h/bar) at normal operating temperatures. The tank is typicallyemptied during the intensive maintenance cleaning, but this isindependent of the periodic deconcentrations and occurs onlyinfrequently, between once every two weeks to once every two months.

Long Aerated Filter Trains

Referring now to FIGS. 5A and 5B, a portion of another embodiment isshown. Components not illustrated in FIG. 5A or 5B are similar to thoseof FIG. 1 and reference may be had to FIG. 1 to understand the generaloperation of the present embodiment. In this embodiment, a secondreactor 70 has a rectangular (in plan view) second tank 120 with aninlet end 72 and an outlet end 74. Preferably, the inlet end 72 is atone short end (as seen in plan view) of the second tank 120 and has aninlet 18 and the outlet end 74 is at the opposite short end of thesecond tank 120 and has a retentate outlet 42. During permeation, thesecond tank 120 is filled with tank water 22 which moves generally in ageneral flow path 76 between the inlet 18 and the retentate outlet 42,the word general meaning that the actual flow path of a volume of tankwater 22 may deviate substantially from the flow path 76 as will bedescribed below, but the average flow of tank water 22 has at least acomponent in the direction of the flow path 76.

Membrane modules 28 are arranged in the second tank 120 in series alongthe flow path 76. Typically the membrane modules 28 are spaced aparthorizontally along the flow path 76 to allow room for associatedapparatus, installation and maintenance, and to provide a small movablevolume of tank water 22 between each membrane module 28. This space ispreferably less than one half of the length (measured along the flowpath 76) of the membrane module 28 and for ZW 500 units is typicallyabout 20 cm. Referring to FIGS. 5A and 5B, greater space is providedabove, below and beside the membrane modules 28. For example, thedistance between the membrane modules 28 and the long walls of thesecond tank 120 is typically about one half of the width of the membranemodules 28 (measured perpendicular to the flow path 76). Preferably, 6or more membrane modules 28 in series are used. More preferably, longtrains of 12 or 16 or more membrane modules 28 in series are used. Wherea large system is required, each membrane module 28 is typically of thesize of a cassette of 6 to 12 ZW 500 units. The total length of all ofthe membrane modules 28 (measured along the flow path 76) excluding thespace between them (also measured along the flow path 76) is at leasttwice, and preferably at least four times, the width of the membranemodules 28 (measured perpendicular to the flow path 76).

Feed water 14 continuously enters the second tank 120 at the inlet 18.Permeate pump 32 continuously withdraws filtered permeate 36 throughmembranes 24 of each membrane module 28 and consolidated retentate 46continuously leaves the second tank 120 through retentate outlet 42. Thepath of a volume of tank water 22, however, passes in series throughsome or all of the membrane modules 28. However, since solids arerejected by the membranes 24, the concentration of solids in the volumeof tank water 22 increases downstream of each membrane module 28 itpasses through. Thus the concentration of solids in the volume of tankwater 22 increases from the inlet 18 to the retentate outlet 42 alongits flow path. Downstream of the membrane module 28 nearest to theretentate outlet 42, the tank water 22 has a high concentration ofsolids of at least five times that of the feed water 14, preferably atleast 14 times that of the feed water 14 and more preferably at least 20times that of the feed water 14. Conversely, tank water 22 near theinlet 18 has a concentration of solids similar to that of the feed water14. In long trains of membrane modules 28 in which the length of themembrane modules 28 (excluding the spaces between them) is four or moretimes their width, up to 75% of the membrane modules 28 operate in tankwater with minimal solids concentration, the concentration of solidsrising sharply only near the outlet 42.

Since the concentration of solids in the tank water 22 rises from theinlet 18 to the retentate outlet 42, membrane modules 28 near the inlet18 operate in water that has a substantially lower concentration ofsolids than the consolidated retentate 46 which flows out of theretentate outlet 42. The last membrane modules 28 (in the direction ofthe flow path 76) have a higher concentration of solids in the tankwater 22 around them and are therefore likely to have reducedpermeabilities. The permeate pump 32 may be placed near the outlet 42 sothat the last membrane modules 28 will receive higher transmembranepressures (relative to more distant membrane modules 28) to overcometheir reduced permeability and provide more nearly even permeate fluxfrom the set of membrane modules. The average concentration of solids inthe tank water 22 is an intermediate concentration in relation to theconcentration of solids in the feed water 14 and consolidated retentate46. If the length of all of the membrane modules 28 (excluding spacesbetween them) is more than twice their width, the area of significantlyreduced concentration can include more than half of the second tank 120.Thus consolidated retentate 46 can be withdrawn having a highconcentration of solids but the average concentration of solids in thetank water 22 is significantly less than the concentration of solids inthe consolidated retentate 46. The average permeability of the membranemodules 28 is increased as fouling occurs less rapidly. Since thepermeability of the membranes 24 decreases rapidly when theconcentration of solids is high, it is preferable if most membranemodules 28 operate in tank water 22 having a concentration of solidsless than 14 times that of the feed water and more preferably less than10 times that of the feed water.

As mentioned above, the path of a volume of tank water 22 passes inseries through some or all of the membrane modules 28. This effect wouldnot occur if the second reactor 70 operated like a completely stirredtank reactor. To counter this possibility, aeration is provided duringthe entire permeation cycle. While aeration is normally considered to bea mixing agent, in the second reactor 70 the inventors believe that theaeration (or alternately an agitator such as a rotating propeller)provided substantially throughout permeation encourages tank water 22 toflow through a plurality of membrane modules 28 sequentially in relationto the flow path when as will be explained below.

With the inlet 18 and outlet 42 at opposite ends of the tank, the tankflow 76 must have an average substantially horizontal flow from inlet 18to outlet 42. The membrane modules 28, however, significantly resistsuch horizontal flow. Accordingly, the bulk of the horizontal flow has atendency to by-pass the membrane modules by flowing beneath, over orbeside them. The inventors believe that if tank water 22 readilyby-passed the membrane modules 28, it would be difficult to avoidsubstantial mixing in the tank 20.

Assuming negligible horizontal flow through the membrane modules 28, thehorizontal velocity of by-pass flow typically ranges from about 0.05 to0.3 m/s, decreasing towards the outlet 42. Typical vertical velocitiesof tank water 22 upwards through the membrane module 28 are of acomparable magnitude, typically 0.05 to 0.2 m/s. Referring to FIGS. 5Aand 5B, a cassettes flow 78 is created in which tank water 22 is drawnup into the bottom of a membrane module 28 released from the top of themembrane module, flows towards the outlet 42 while descending to thebottom of the tank 20 where it is entrained in a second membrane module28 and so on. The cassette flow 78 has a component flowing downwardsbesides the membrane modules 28 (as shown in FIG. 5B) and a componentflowing downwards between the membrane modules 28 (as shown in FIG. 5A).The inventors have observed that the component flowing downwards besidesthe membrane modules 28 is about 90% of the cassette flow 78. Theinventors believe that the flow component flowing downwards between themembrane modules 28 is much smaller than the flow downwards besides themembrane modules 28 because distance to the walls of the second tank 120is greater than the distance between membrane modules 28 and eachmembrane module 28 is surrounded by an upwards flow of tank water 22.Together, these factors result in a higher shear force inhibiting tankwater 22 from flowing downwards between membrane modules 28.

Cassette flow 78 created within a first membrane module 28 and flowingdownwards between membrane modules 28 likely mixes in part with tankwater 22 similarly flowing downwards in the cassette flow 78 of anadjacent membrane module 28 and becomes part of the cassette flow 78 ofthe adjacent membrane module 28. Thus, a mixing flow 80 of tank water 22circulating around a membrane module 28 may be drawn towards the inlet18 by an upstream membrane module 28 or towards the retentate outlet 42by a downstream membrane module 28. The degree of mixing in the secondtank 120 may be expressed in relation to a recirculation rate defined asthe flow rate of the cassette flow 78 through the centre of the membranemodules 28 divided by the flow rate of feedwater. Surprisingly, inmodelling experiments to be described below, if the cassette flow 78produces no net flow towards the inlet 18 or retentate outlet 42 (i.e.it is symmetrical about the membrane module 28) then the concentrationof solids in the tank water 22 still increases along the flow path 76even at unusually high recirculation rates and even under the assumptionthat the component of cassette flow 78 downwards between adjacentmembrane modules 28 is unusually high.

Although it is usually unnecessary, an operator may minimize mixingbetween adjacent membrane modules 28 so that the concentration of solidsin the second tank 120 will rise only near the retentate outlet 42 ofthe second tank 120 resulting in increased permeability in a greaternumber of membrane modules 28. Alternately, the second tank 120 can bemade of a plurality of filtering zones wherein the outlet of a firstfiltering zone is connected to the inlet of a downstream filtering zone.The filtering zones may be created by breaking the second tank 120 intoa plurality of containers or with baffles 82 at the upper upstream edgeor lower downstream edge of a membrane module 28 to restrict backflows80 flowing towards the inlet 18. Preferably, baffles are installed onlyon membrane modules 28 located near the retentate outlet 42 where therate of flow in the flow path 76 is reduced.

Membrane Modules in Series

Referring now to FIGS. 6 and 7, another second membrane module 110having hollow fibre membranes 24 is shown in elevation and plan viewrespectively. The membranes module 110 is similar to that shown in FIG.4 but the perimeter of the second membrane module 110 is surrounded by anon-porous casing 124 which defines a vertically oriented flow channel126 through the second membrane module 110. Similar modules can becreated with membrane modules 28 as shown in FIGS. 2, 3 and 4 or withtubular or flat sheet membranes as described above.

Referring now to FIG. 8, a third reactor 128 has a plurality of secondmembrane modules 110 in a plurality of filtration zones 130. The thirdreactor 128 has a feed pump 12 which pumps feed water 14 to be treatedfrom a water supply 16 through an inlet 18 to a third tank 140 where itbecomes tank water 22. During permeation, the feed pump 12 is operatedto keep tank water 22 at a level which covers the membranes 24. Thepermeate collector 30 of each second membrane module 110 is connected toa set of pipes and valves as shown including a pair of permeate valves144 and a pair of backwash valves 60. To withdraw permeate from a secondmembrane module 110, its associated permeate valves 144 are opened whileits backwash valves 60 are closed and an associated permeate pump 32 isturned on. The resulting suction creates a transmembrane pressure(“TMP”) from the outside of the membranes 24 to their lumens 25. Themembranes 24 admit a flow of filtered permeate 36 which is produced foruse or further treatment at a permeate outlet 38. From time to time, apermeate storage valve 64 is opened to maintain a supply of permeate 36in a permeate storage tank 62. Such an arrangement allows permeate 36 tobe withdrawn from each filtration zone 130 individually. Preferably, thepermeate pumps 32 are operated to produce a similar flux of permeate 36from each filtration zone 130. Since solids concentration in eachfiltration zone 130 differs, as will be explained further below, thistypically requires each permeate pump 32 to be operated at a differentspeed. Alternatively, the second membrane modules 110 in differentfiltration zones 130 can be connected to a common permeate pump 32. Thiswill result in some variation in flux between the filtration zones 130(because the downstream second membrane modules 110 are likely to foulfaster), but the amount of variation can be minimized by locating thepermeate pump 32 near the outlet 42 as described above or by variationsin aeration, backwashing and packing density to be described below. Withany of these techniques, the second membrane modules 110 can be made tohave similar permeate fluxes.

Tank water 22 which does not flow out of the third tank 140 through thepermeate outlet 38 flows out of the third tank 140 through a drain valve40 and retentate outlet 160 to a drain 44 as consolidated retentate 46.Additional drains in each filtration zone 130 (not shown) are alsoprovided to allow the third tank 140 to be drained completely fortesting or maintenance procedures. The consolidated retentate 46 is richin the solids rejected by the membranes 24. Flow of the consolidatedretentate 46 may be assisted by a retentate pump 48 if required. Theinlet 18 and retentate outlet 160, however, are separated by thefiltration zones 130. Partitions 176 at the edges of the filtrationzones 130 force the tank water 22 to flow sequentially through thefiltration zones 130 in a tank flow pattern 178. The partitions 176 havedecreasing heights in the direction of the tank flow pattern 178 suchthat a difference in depth from one filtration zone 130 to the nextdrives the tank flow pattern 178. The difference in depth betweenpartitions 176 varies with different applications, but is unlikely to bemore than 1 m between the first and last partition 176. Alternatively,flow from one filtration zone 130 to the next could be through conduitsand driven by differences in depth from one filtration zone 130 to thenext or driven by pumps.

While in normal operation, feed pump 12 substantially continuously addsfeed water 14 to the third tank 140 while one or more permeate pumps 32substantially continuously withdraw permeate 36. The process istypically operated to achieve a selected recovery rate defined as theportion of feed water 14 removed as permeate 36 (not including permeate36 returned to the third tank 140 during backwashing to be describedfurther below) expressed as a percentage. The selected recovery rates istypically 90% or more and preferably 95% or more.

As the tank water 22 moves from one filtration zone 130 to the next, thesolids concentration increases as solids lean permeate 36 is removed.This effect may be illustrated by a simplified example in which thethird reactor 128 shown in FIG. 8 is operated at an overall recoveryrate of 95%. 100 flow units of feed water 14 having a concentration of 1enters the third tank 140 at the inlet 18. According to the recoveryrate, 95 flow units leave the third tank 140 as permeate 36 while 5 flowunits leave the third tank 140 as consolidated retentate 46. Assumingequal production from each second membrane module 110, 19 flow unitsleave the third tank 140 as permeate 36 in each filtration zone.Assuming further (a) that all solids are rejected by the membranes 24and (b) that the concentration of solids in a filtration zone 130 equalsthe concentration of solids in the flow to the next filtration zone 130,the following chart is generated by applying a mass balance of fluid andsolids to each filtration zone 130. Maximum Fil- Concen- Concen- trationtration Permeate Flow to tration Zone Flow In in inflow Flow out NextZone in Zone 1 100 1 19 81 1.2 2 81 1.2 19 62 1.6 3 62 1.6 19 43 2.3 443 2.3 19 24 4.2 5 24 4.2 19 5 20 (to drain)

In comparison, if there were no filtration zones 130 and the entirethird tank 140 was fully mixed, the tank water 22 would have aconcentration 20 times that of the feed water 14 throughout. Byproviding a series of sequential filtration zones 130 between the inlet18 and retentate outlet 160, the concentration of solids in the tankwater 22 in most of the filtration zones 130 is significantly reduced.The reduced concentration of solids results in significantly reducedfouling of the second membrane modules 110 in the applicable filtrationzones 130. Among other benefits, less chemical cleaning is required forthese second membrane modules 110. Further, reduced aeration andbackwashing routines are sufficient for individual filtration zone 130or groups of filtration zones 130 with reduced concentrations of solids.Unlike the embodiment above without separate filtration zones 130,aeration is not required to prevent tank water 22 from by passing themembrane modules and so less or even no aeration can be provided duringsubstantial periods. Further, by forcing tank water 22 to flow throughthe casings 124, aeration is not required to create local circulation oftank water 22 around second membrane modules 110. Accordingly, space inthe third tank 140 is not required for downcomers and the secondmembrane modules 110 can occupy 80% or more of the plan area orfootprint of the tank 140.

Aeration is provided, nevertheless, to scour the membranes 24 which canoccur without creating an air lift effect in the tank water 22. Toprovide aeration, an air supply 50 associated with each filtration zone130 is operable to blow air, nitrogen or other suitable gases throughair distribution pipes 54 to a header 170 attached to a plurality ofaerators 56 below the second membrane module 110. During aeration, theaerators 56 emit scouring bubbles 58 below the second membrane module110 which rise through the membranes 24. Thus aeration can be providedto each filtration zone 130 individually.

The second membrane module 110 in each filtration zone 130 can also bebackwashed individually by closing its associated permeate valves 144and opening its associated backwash valves 60. The associated permeatepump 32 (or alternatively, a separate pump) is then operated to drawpermeate 36 from the permeate storage tank 62 and pump it through thepermeate collector 30 and, ultimately, through the membranes 24 inreverse direction relative to permeation. Preferably the second membranemodules 110 in adjacent filtration zones 130 are not backwashed at thesame time. The backwash typically lasts for between 15 seconds and oneminute and involves a flux one to three times the permeate flux but in areverse direction. Accordingly, the level of the tank water 22 in thebackwashed filtration zone 130 rise temporarily causing more tank water22 to flow to the next filtration zone 130. Preferably, the downstreampartition 176 in each filtration zone is sufficiently lower than theupstream partition 176 such that tank water 22 does not flow over anupstream partition 176 during backwashing.

To achieve a higher density of membranes 24 in the third tank 140, thesecond membrane modules 110 are sized to nearly fill each filtrationzone. Further, the second membrane modules 110 are positioned such thattank water 22 or feed water 14 flowing into a filtration zone 130 mustflow first through the flow channel 126 of the second membrane module110. The tank flow 178 thus generally flows downwards through eachsecond membrane module 110 then upwards outside of each second membranemodule 110 and over the downstream partition 176. Accordingly, the tankflow 178 is transverse to the membranes 24 and generally inhibitssolids-rich zones of tank water 22 from forming near the membranes 24.During backwashing, the tank flow 178 may temporarily flow upwardsthrough the second membrane module 110 if the top of the casing 24around the second membrane module 110 is located near the normal levelof the tank water 22. Such reverse flow does not significantly effectthe general tank flow 178 but it is preferred if during backwashing thetank water 22 does not overflow the second membrane module 110. In thisway, after backwashing stops, there is a momentarily increased tank flow178 which assists in moving solids from near the bottom of the secondmembrane module 110 to the next filtration zone 130. For second membranemodules 110 with minimal aeration, the tank flow through a secondmembrane module 110 approaches a plug flow and there is an increase inconcentration of solids as the tank water 22 descends through the secondmembrane module 110. Accordingly, membranes 24 near the top of thesecond membrane module 110 experience a concentration of solids evenlower than that predicted by the chart above, and comparatively moresolids attach to the lower membranes 24. During aeration, the bubbles 56rise upwards against the tank flow 178 and no space for downcomers isrequired in the filtration zones 130.

Combining Long Aerated Filter Trains and Membrane Modules in Series withRapid Flush Deconcentration.

In another embodiment of the invention, the embodiments described withreference to FIGS. 5 and 8 are operated in cycles including rapid flushdeconcentrations. The resulting temporal reduction in concentration ofsolids produced by the deconcentrations works to further the effect ofthe spatial reductions in concentration of solids. With reference toFIGS. 5A and 5B or 8, at the start of a cycle, the second tank 120 orthird tank 140 is filled with tank water 22. Filtered permeate 36 iswithdrawn from the second tank 120 or third tank 140 while drain valves40 remain at least partially and preferably completely closed so thatthe tank water 22 becomes more concentrated with solids until adeconcentration is indicated as described above.

Permeation continues while the second tank 120 or third tank 140 isdeconcentrated by simultaneously withdrawing consolidated retentate 46from the second tank 120 or third tank 140 and increasing the rate thatfeed water 14 enters the second tank 120 or third tank 140 to maintainthe level of tank water 22 above the membranes 24 during the flushingoperation. When the tank water 22 is deconcentrated by a rapid flushwhile permeation continues, the volumes of water removed from the secondtank 120 or third tank 140 can be the same as those described above.Preferably, however, since only the downstream portion of the secondtank 120 or third tank 140 contains tank water 22 at a highconcentration of solids, lower flush volumes may be used since only thedownstream part of the tank water 22 requires deconcentration. With theapparatus of FIG. 8 or with the apparatus of FIGS. 5A and 5B in whichaeration is turned of during the deconcentration, between 20% and 75% ofthe volume of the tank water 22 is preferably removed and morepreferably between 20% and 50%. If there is aeration at the time of thedeconcentration with the apparatus of FIGS. 5A and 5B, between 40% and150% of the volume of the tank water 22 is preferably flushed, and morepreferably between 40% and 75%. With the apparatus of FIG. 8,deconcentrations are preferably performed directly after backwashingevents so that the increased flux of the tank flow 178 will entrain moresolids.

Deconcentrations can also be performed by stopping permeation and theflow of feed water 14 into the second tank 120 or third tank 140 whileretentate 46 is withdrawn. The level of the tank water 22 drops and sothe second tank 120 or third tank 140 must first be refilled beforepermeation can resume. As suggested above, this process avoids dilutionof the retentate 46 with feed water 14 but also interrupts permeation.In the apparatus of FIG. 8, however, the last filtration zone 130 can bedrained separately while permeation is stopped in that filtration zone130 only. Compared to a process in which a tank is emptied, suchdeconcentrations are performed more frequently but involve less volumeeach which reduces the capacity of the drain 44 required. In addition,this technique advantageously allows tank water 22 rich in solids to bewithdrawn while permeating through most membrane modules 28 and withoutdiluting the retentate 46. While the flow of feed water 14 can bestopped completely while the last filtration zone 130 is emptied, theflow path over the last partition 176 is preferably fitted with aclosure such as a gated weir 180 or a valved conduit. The closure isshut at the start of the deconcentration which prevents tank water 22from flowing over the partition 176 after the drain valve 40 is opened.Retentate pump 48 may be operated to speed the draining if desired. Feedwater 14 continues to be added to the third tank 140 during thedeconcentration until the level of the tank water 22 rises in thedownstream filtration zones 130 to the point where appreciable reverseflow may occur across the partitions 176. After the last filtration zone130 is emptied, retentate pump 48 is turned off (if it was on) and drainvalve 40 is closed. The closure is opened releasing an initially rapidflow of tank water 22 which fills a portion of the last filtration zone130. The flow of feed water 14 is increased until the remainder of thelast filtration zone 130 is filled. To avoid damage to the membranes 24during rapid flows of tank water 22, baffles (not shown) are preferablyinstalled above the second membrane modules 110 to direct the flow anddissipate its energy.

Tapered Aeration

With the embodiments discussed with reference to FIGS. 5 and 8,additional advantage is achieved by varying the amount of aeration alongthe second tank 120 or third tank 140. For this purpose, the apparatusin FIGS. 5A and 5B is fitted with a separate aeration system for eachmembrane module 28 as shown in FIG. 8, the connection between the airdistribution pipes 54 and selected aerators 56 are fitted withrestricting orifices or, preferably, each aerator 56 has a flow controlvalve associated with it. Membrane modules 28 or second membrane modules110 operating in tank water 22 with low concentration of solids areaerated less forcefully, preferably based on the concentration of solids22 in the tank water surrounding each membrane module 28 or secondmembrane module 110. The furthest upstream membrane module 28 or secondmembrane module 110 is exposed to the lowest concentration of solids andthus receives the least amount of air, subject in the embodiment ofFIGS. 5A and 5B to the need to entrain tank water 22 that wouldotherwise by-pass the membrane modules 28. The most downstream membranemodule 28 or second membrane module 110 is exposed to the highestconcentration of solids and receives the most aeration.

Typically, all aerators 56 are built to the same design and are ratedwith the same maximum air flow that can be passed through them. Theminimum amount of air flow is typically about one half of the ratedmaximum air flow, below which the aerator 56 may fail to aerate evenly.Preferably, the upstream one half or two thirds of the membrane modules28 or second membrane modules 110 are aerated at 50% to 60% of the ratedcapacity of the aerators 56 and the remaining membrane modules 28 orsecond modules 110 are aerated at 80% to 100% of the rated capacity, theincrease being made either linearly or in a step form change. Such avariation approximately follows the increase in solids concentration inthe tank water 22.

Tapered Backwashing

Additionally or alternately, tapered backwashing may be employed.Membrane modules 28 or second membrane modules 110 operating in tankwater 22 with low concentration of solids require less backwashing. Thefurthest upstream membrane module 28 or second membrane module 110 isexposed to the lowest concentration of solids and receives the leastamount of backwashing whereas the most downstream membrane module 28 orsecond membrane module 110 is exposed to the highest concentration ofsolids and receives the most backwashing. The amount of backwashing istypically increased between these extremes using a lower amount ofbackwashing for the upstream one half or two thirds of membrane modules28 or second membrane modules 110 and then increasing either linearly orin step form to a higher amount for the remaining membrane modules 28 orsecond membrane modules 110. For this purpose, the apparatus in FIGS. 5Aand 5B is fitted with a separate backwashing system for each membranemodule 28 as shown in FIG. 8.

Backwashing can be varied in both frequency or duration. Preciseparameters depend on the feed water 14 and other variables but typicallyrange from a 10 second backwash once an hour to a 30 second backwashonce every five minutes, the lower amount being near the former regimeand the higher amount being near the latter.

Flow Reversal

In addition or alternatively, to reduce excessive loss of permeability(because some long term fouling effects are irreversible) and to preventuneven damage to different membrane module 28 when tapered aeration isused, the direction of tank flow 78 may be reversed periodically byproviding an inlet 18 and retentate outlet 46 at opposite ends of thesecond tank 120 or third tank 140. Preferably the reversal is done afterperiodic chemical cleaning which is required approximately every twoweeks to two six months and often requires draining the second tank 120or third tank 140. Such flow reversal allows the membranes 24 near theends of the second tank 120 or third tank 140 to be operated at times insolids lean tank water 22 which substantially increases their usefullife. Such flow reversal can be accomplished in the embodiment of FIG. 8with some modification but is inconvenient, the method being more suitedto the embodiment of FIGS. 5A and 5B.

Variable Packing Density

In general, membrane modules 28 or second membrane modules 110 withlower packing density are preferred in solids rich tank water 22. Thereduced packing density allows bubbles 58 to reach the membranes 24 moreeasily and increases the cleaning or fouling inhibiting effect ofaeration. For solids lean tank water 22, higher packing density isdesirable as more membrane surface area is provided for a given volumeof second tank 120 or third tank 140. Alternatively or additionally, thepacking density of downstream membrane modules 28 or second membranemodules 110 is reduced relative to upstream membrane modules 28 orsecond membrane modules 110 with a corresponding change in the size ofthe filtration zones 130. Preferred upstream packing densities vary from20% to 30%. Preferred downstream packing densities vary from 10% to 20%.

Alternate Tank Shapes

Referring to FIG. 9, a round tank 220 is used. Inlet 18 is located atone point on the circumference of the tank 220 and the retentate outlet42 is located in the middle of the tank 220, or alternately (as shown indashed lines) at another point on the circumference of the tank 220.Membrane modules 28 or second membrane modules 110 are placed in a ringaround the centre of the tank 220 in a horizontally spaced apartrelationship. An internal divider 222 in the tank 220 is used to createa circular flow path 276 between the inlet 18 and the retentate outlet42.

Referring to FIG. 10, a low aspect ratio or square tank 320 is used.Inlet 18 is located at one point on the tank 320 and the retentateoutlet 42 is located at another point on the tank 320. An internaldivider 322 in the tank 320 is used to create a flow path 376 betweenthe inlet 18 and the retentate outlet 42. Membrane modules 28 or secondmembrane modules 110 are placed in series along the flow path 376 in ahorizontally spaced apart relationship. Alternately, in a variationshown in dashed lines, the internal divider 322 is a wall betweenseparate tanks joined in series by fluid connector 324.

Where the round tank 220 or low aspect ratio or square tank 320 is usedin place of the third tank 128, partitions 176 are provided betweensecond membrane modules 110.

Example 1

A submerged membrane reactor according to FIGS. 5A and 5B was modelledusing experimental data from tests under a continuous process andassuming that the local flow around the membrane modules is symmetricalin the upstream and downstream directions—ie. the overall tank flowtowards the outlet was discounted. The system comprises a tank 16.4metres long, 3.28 metres wide with an average depth of water of about2.5 metres. The tank of the reactor contains 12 membrane modules eachbeing a cassette of 8 ZW500 membrane modules. Each cassette isapproximately 1.82 metres high, 1.83 metres wide and 0.71 metres longalong the flow path and placed in the tank so as to leave approximately0.75 m between the edge of the cassettes and the long walls of the tank.The cassettes are spaced evenly between the inlet end and outlet end ofthe tank. Transmembrane pressure is maintained at a constant 50 kPathroughout the model and the permeability of the membranes at any timeis determined by a chart based on experimental data relating sustainablepermeabilities to the concentration of solids in the water surroundingthe membranes. The flow rate of feedwater and consolidated retentatewere adjusted as necessary for a recovery rate of 95%. The feed water isassumed to have an initial concentration of solids of 10 mg/l.

In a first series of modelling experiments, the membrane modules wereassumed to be continuously aerated at a constant rate that would resultin a total cassette flow of about 3800 litres per minute (for a velocityof 0.05 m/s) upwards through the centre of each cassette and a downwardflow of 1900 litres per minute down each of the upstream and downstreamedges of each membrane module. The model assumes that all of thiscassette flow flows downwards between adjacent membrane modules. Themodel also assumes that the water between adjacent membrane modulesmixes completely such that 50% of the water flowing downwardly along theedge of a cassette, or 950 litres per minute is entrained in the flowmoving upward through each adjacent membrane module. The model furtherassumes that any by-pass flow around the membrane modules 28 along thesides of the tank is negligible.

In a first test, the test reactor was modelled in continuous bleedoperation, that is filtered permeate, consolidated retentate and feedwater are all flow continuously. The concentration of solids at eachcassette is shown in FIG. 11 and increases from approximately 20 mg/l to200 mg/l. As shown, the average concentration of solids surrounding thecassettes is significantly reduced while the consolidated retentate hasa concentration of solids of 200 mg/l. The expected permeability of themembrane modules is also shown in FIG. 11 which suggests that such areactor will operate continuously with an average permeability of over200 L/m²/h/bar with 8 of 12 membrane modules operating withpermeabilities above that average. In comparison, in a conventionalfully mixed process operating at the same 95% recovery rate, theconcentration of solids throughout the tank would be 200 mg/l and allmembrane modules would operate at a permeability of approximately 155L/m²/h/bar which would exceed the recommended operating conditions ofthe ZW500 membrane modules.

In a second modelling experiment, the first modelling experiment wasmodified to assume that the tank was emptied every four hours whilepermeation stops but with other parameters as above. The results of thisexperiment are shown in FIG. 12 which indicates that all cassettes canoperate at a permeability above 200 L/m²/h/bar with this process.

In a third modelling experiment, the first modelling experiment wasmodified to assume that the tank was deconcentrated every four hours bywithdrawing consolidated retentate while increasing the flow rate offeedwater while permeation continues but maintaining a 95% recoveryrate. The results of this experiment are shown in FIG. 13 which againindicates that all cassettes can operate at a permeability above 200L/m²/h/bar with this process.

In a fourth modelling experiment, varying rates of aeration and thusvarying recirculation rates were used. The results of this experimentare shown in FIG. 14 and indicate that recirculation rates of 25%produce drastically lowered concentrations of solids in the watersurrounding a majority of cassettes and that even at a generousrecirculation rate such as 100% or 165%, a majority of cassettes areexposed to water having a significantly reduced concentration of solids.

In a fifth modelling experiment, the model of the first modellingexperiment was repeated without deconcentrations assuming a varyingnumber of cassettes between 1 and 16. As shown in FIG. 15, the averageconcentration in the tank is reduced with even 2 or 4 cassettes and thatwith 6 or more cassettes, the average concentration of solids in thetank is nearly half of the concentration (200 mg/l) that would occur inthe model with a conventional fully mixed process.

In a sixth modelling experiment, the model of the first modellingexperiment was repeated without deconcentrations but with the recoveryrate varying from 90% to 99% and compared to a model of a conventionalfully mixed continuous bleed process operating at the same recoveryrates. As shown in FIG. 16, a conventional process operating at a 95%recovery rate will have an average concentration of solids in the tankof 200 mg/l. The process and apparatus modelled for a long aeratedfilter train could be operated at a recovery rate of approximately 97.5%with the same average concentration of solids which would result in 50%less consolidated retentate to be disposed of.

Example 2

In this example, an actual experimental apparatus was constructed andoperated similar to FIGS. 5A and 5B. The dimensions of the tank were asdescribed for the modelling experiments above, but 16 cassettes of 8ZW500 membrane modules each were installed consecutively 20 cm apartfrom each other in the direction of the flow path and used with constantaeration. The apparatus was run continuously without deconcentrations ata recovery rate of 91%. The yield was maintained at a constant 93litres/second with 9.4 litres/second of consolidated retentatecontinuously leaving the tank. Colour was monitored at each cassettealong the tank as an indicator of the concentration of solids at eachcassette. As shown in FIG. 17, the concentration of solids increasedsignificantly only in the downstream 20% of the tank with most cassettesoperating in relatively clean water.

Example 3

An experiment was conducted with a water filtration system similar toFIGS. 5A and 5B comprising 12 cassettes of 8 ZW 500 modules each. Theaeration was linearly increased from about 13.6 Nm³/h for each ZW 500for the first cassette to about 22.1 Nm³/h for each ZW 500 for the lastcassette. This resulted in a total reduction in system aeration from theusual 1989 Nm³/h to 1785 Nm³/h, more than a 10% reduction while the rateof membrane fouling remained the same and foaming was considerablyreduced. In this experiment, the system recovery was 84% while the watertemperature was at 22.5 degrees C.

It is to be understood that what has been described are preferredembodiments of the invention. The invention nonetheless is susceptibleto certain changes and alternative embodiments without departing fromthe subject invention, the scope of which is defined in the followingclaims.

1. A process for treating water comprising the steps of: a) providingone or more membrane modules in a generally vertically oriented flowchannel; b) flowing feed water into the flow channel from above the oneor more membrane modules to immerse the one or more membrane modules; c)applying a suction to the one or more membrane modules to withdrawpermeate; and, d) removing unpermeated water from the flow channel frombelow the one or more membrane modules.
 2. The process of claim 1further comprising a step of providing gas bubbles to scour the one ormore membrane modules.
 3. The process of claim 1 wherein steps (b), (c)and (d) are performed simultaneously and continuously over a period oftime.
 4. The process of claim 3 further comprising a step of scouringthe one or more membrane modules during the period of time.
 5. Theprocess of claim 3 wherein the rate of feed flow is between 1.3 to 5.2times the rate of permeate flow during the period of time.
 6. Anapparatus for treating water comprising; a) a tank; b) one or moremembrane modules in the tank; c) a non-porous casing surrounding the oneor more membrane modules and defining a generally vertical flow channelcontaining the one or more membrane modules; d) a source of suction incommunication with the one or more membrane modules; e) an inlet to thetank; and, f) an outlet from the tank, wherein, g) the apparatus isconfigured such that water in the tank flows into the top of the casingand out of the bottom of the casing.
 7. The apparatus of claim 6 wherein80% or more of the footprint of the tank is covered with membranemodules.
 8. The apparatus of claim 6 having a plurality of non-porouscasings each defining a vertical flow channel containing one or moremembrane modules, the apparatus configured such that water in the tankflows into the top of each casing and out from the bottom of eachcasing.